2003 SANTE battery compartment enlarging

[core-rider]

So against everyone's better judgement I went ahead and started my battery compartment enlargement project in my 2003 SANTE. A little background, this is to install 2 batteries in the port side compartment for stereo power and enlarge the starboard side so a Group 27 will fit for the house side. I made the port side large enough to fit Group 27's as well. After making some careful measurements before and after I removed the carpet all that was left to do was start cutting.

PSA - For those of you that are squeamish turn away now!!! What you are about to see my disturb you...

Measuring and taping off cut lines...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_3671.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_3674.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0059.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0060.jpg

First cuts... I used a Ridgid "Jobmax" to make the cuts with. It did a great job but goes through batteries every 30 minutes so 2 are a must! I tried a jigsaw at one point but this fiberglass ate through blades like crazy. 6" of cutting and the blades was useless.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0063.jpg

First few pieces removed... I used a hacksaw blade to cut the foam by hand, but later mover to a drywall saw...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0064.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0065.jpg

All the sides gone on the starboard box...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0066.jpg

All the foam removed on the starboard battery box. I wasn't originally going to remove all the foam to the hull, but I ran into some moist foam at the very bottom and wanted to investigate more. Never figured out where the moisture came from, but the further back toward aft I went the more I found.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0068.jpg

Now to start on the port side...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0069.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0070.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0071.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0072.jpg

I ran into a surprise on the port side that gave me a bit of a scare, but I was too far gone to stop now. A lock washer made its way into the laminating process somehow and just happened to be right in the middle of one of my cuts. My heart sank a little when I heard the multi-tool change pitch at first.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0074.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0076.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0077.jpg

All the fiberglass and foam now gone on the port side as well... The tube is a piece of PVC that goes through the stringer into the bilge to allow water to drain. I will cut it back during the laminate process.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0078.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0079.jpg

At this pint all the cutting was done, foam removed, and I took a step back to see what I had accomplished. That's when the feeling that a person gets in any project hit me... "What have I done?!?!"
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0080.jpg

More pics to come as the laminating process begins... Time to ring in the New Year and have a drink... or a dozen!

[TxJole]

Looks good, see you havent got that trans valve on yet. Did you get it?

[core-rider]

Yeah I got it, just haven't gotten around to putting it on yet. Thanks again...

[2004196]

Great job Jason! I'm impressed with your courage and workmanship. I also tackle things such as this and know the feeling well of that first hole/cut and whether or not it will end up as an "OH SH*T" moment! Once you cross that point of no return you can only proceed slowly and with confidence. When things go well, the satisfaction is well worth the risk. Thanks for sharing the pics in such detail as this will no doubt help others have the confidence to take on like projects.

Ron

[n3]

Jason,

Great work and I can't wait to see the finished project.

Mark @ N3

[mnwakerider]

Really looking forward to how you finish this up. Its a great start so far. I have an 03 SAN and this is on my winter list as well.

Thanks!

[TX-Foilhead]

How's this going? It's got me thinking up all kind of things to do.

[core-rider]

Unfortunately not much progress has been made because my schedule has been too full. I did get new foam sprayed in place though. I just need to trim it down a bit and then I can start with fiberglass layup.

[h2ohangtime]

Jason, I just finally caught this (I've been slacking on my PN attendance lately). It looks great. I wish our SAN had dual battery boxes in it like yours did originally. We only had one on the port side. Just goes to show that CC didn't have a standard for them coming out of the factory. Anyway, keep up the great work and post up the progress. As long as you do a good job with the lay-up, you'll really enjoy the extra space for the batteries. Nice job...

[core-rider]

Been busy the past few weeks and haven't gotten much accomplished. I did get some new foam sprayed in and trimmed it back down to the dimensions I need. Now I need to fill just a few voids in the foam and start cutting the fiber mat to get ready for lay-up. Few more progress pics...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0095.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0096.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0097.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0098.jpg

[core-rider]

Progress made! Got the voids in the foam filled... I was a bit worried if I could layup the fiberglass strong enough to hold up the weight of the batteries so I added a piece of 1/8" HDPE to the bottoms of both compartments. This will also allow for a nice flat base for the batteries to sit on sine my foam is just a bit uneven.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0129-1.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0130-1.jpg

I cut out some 10oz. fiberglass cloth. I'm laying the cloth in two different directions to hopefully add strength to the floor while covering the walls. These pics only show the first layer before resin.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0137.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0139.jpg

First layer with resin...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0140.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0141.jpg

Now with the second layer of fiberglass mat resined in place.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0142.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0144.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0143.jpg

I'm thinking about moving to some chopped stand mat just to build up the thickness of the layup some. I will make a choice once these layers have cured.

[DanielC]

Chopped strand is your weakest fiberglass available. I would continue to build with cloth, or woven roving, Put the next layer of cloth or roving on a 45 degree angle to the direction the other fabric is laid up.

[core-rider]

That's basically what I have found in my research. I'm sticking with the cloth and continuing to lay it in different directions.I checked it this morning and it cured pretty sturdy, just need to get more layers to build up thickness and strength.

[core-rider]

Added a layer of 18 oz. woven cloth to both boxes today.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0146.jpg
Port box before resin...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0147.jpg
Starboard box before resin...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0148.jpg
Both sides after resin...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0149.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0150.jpg

I will add at least one more layer of the 18 oz. woven cloth before going back to the 10 oz. cloth for final finishing.

[core-rider]

Adding some 18 oz. roving to the corners...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0151.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0152.jpg

[tstoll]

Where did you purchase all the cloth and resin?

[2004196]

Ccore-rider,

I still commend you on your workmanship, very impressive!

[core-rider]

Where did you purchase all the cloth and resin?

fiberglasssite.com

They are really helpful answering all my questions and have everything yuo could need to do a rpoject llike this. Shipping is quick too from Ohio to Alabama is only about 3-4 days from time of order. They also have a great online guide that can be printed out to answer any questions you may have.


Ccore-rider,

I still commend you on your workmanship, very impressive!

Thanks man, this is definately a big project! Was hoping to be done by now, but have too many irons in the fire.

[core-rider]

Got the final few layers of fiberglass done. Just waiting on the resin to cure so I can cut to holes for the water drain back into the bilge, paint the compartments black, then I can put the carpet back in place and start putting this whole mess back together. Last layers of 18 oz. woven roving...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0157.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0158.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0159.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0160.jpg

Final layer of 10 oz. cloth to finish things up nice and give a somewhat smooth finish.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0161.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0162.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0163.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0164.jpg
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http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0168.jpg

[core-rider]

Ready to start putting thing back together now! Got the drain holes drilled, resined and painted both boxes.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0171.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0172.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0173.jpg
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http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0175.jpg

[core-rider]

Some actual visible progress made tonight! Got the carpet laid back down, trimmed to fit the new openings, and re-installed the floor over the fuel tank. Also spent some time running my 1/0 gauge power cables to may new amp rack from the batteries on the port side and mounted the new Perko selector switch on the starboard side. No pics of that just yet... I will post stereo mods in the near future.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0179.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0180.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0177.jpg

[core-rider]

Got the "house batteries" in place and wired tonight, mounted the Perko switch, all I just need to buy a third battery and the power side of the system will be done.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0181.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0182.jpg

2 - Group 24 batteries wired in parallel. Once these go bad I will replace them with Group 27's.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0183.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0184.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0185.jpg

Used some scrap pieces of HDPE from my amp rack to attach the 1/0 gauge cables running from bow to stern...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0195.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0192.jpg

Here are some pics of my amp rack which is the whole reason I took on this little project. I used HDPE (Starboard) for the rack. It holds a WS Syn4 for the tower speakers, Kicker IX1000.1 for the subs, and Kicker 500.4 for the in-boat speakers. I have the taped up right now for protection until I'm done working.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0191.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0190.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0189.jpg

Template for the amp rack...
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_3640.jpg

HDPE sheet before and after cutting. The circle in the middle marks a hole that I have not cut yet of the thru-hull fitting the glove box drain has to go through.
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_3648.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_3651.jpg

Pre-wired as much as I could before installation. Some people like to hide all the wiring, but I like the looks as long as it is neat. I wish I could have done a better job of the power cables crossing over one another, but it couldn't be avoided. The smaller black box above the Syn4 is for an auxiliary power source. It has 6 separate fused circuits. I'm using it for the remote turn-on relay for the amps. It will eventually power LEDs of whatever I need in the future.
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_3680.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_3692.jpg

[vanislwake]

That's some serious power! Very nice work, can I ask how you secured the amp rack to the hull? My boat has a piece approximately 12"x12" already secured to the hull where one amp was but now I have 3 amps.

[GAGS]

Great job CR! You should be commended on your workmanship and attention to detail, well done.

[core-rider]

That's some serious power! Very nice work, can I ask how you secured the amp rack to the hull? My boat has a piece approximately 12"x12" already secured to the hull where one amp was but now I have 3 amps.

I previously installed a second board to the hull with Liquid Nails a few years ago to add a second amp. I used it and the factory amp board as backers and just screwed the new board to it.

[Texan1554]

Looks great man, nice work.

[Cam003]

I am just wondering how many layers of glass you laid down. i may be doing this same mod in the near future, do to a very similar stereo setup.

[RogueOne]

Beautiful craftsmanship!

[core-rider]

I am just wondering how many layers of glass you laid down. i may be doing this same mod in the near future, do to a very similar stereo setup.

I started with a 1/8" piece of HDPE just to make sure I had some thickness on the bottom of the compartments and have a nice flat surface to start with. I put down 2 layers of a 10 oz. fiberglass cloth first, then a layer of 18 oz woven roving. I went back after that and added some 18 oz woven roving to each corner to help build them up a bit more. 2 more layers of 18 oz. woven roving in each compartment, then one more layer on 10 oz. fiberglas cloth for a nice smooth finish. Each of the woven roving layers I went eavy on the resin build up to make sure those layers wee good and saturated. In all the base is probably 1/4" thick and the sides are probably 1/8" thick. Everything feels really strong and solid. I know it's probably not as thick as the factory boxes were, but they had some serious build up going on.

[core-rider]

Got everything powered up Wednesday night and didn't see smoke so I guess I wired everything up correctly. Did a little pre-tuning in the garage but couldn't really crank it up without bothering neighbors. Been cleaning interior since then getting ready to take the boat out tomorrow and really get the gains set and do a little rust shaking wake set. Will post up some pics later today of finished project with seat bse in place. Everything fit great, almost like I had measured and planned it out or something! :-D

[core-rider]

Here are the pics of the finished product with the seat base back in place... I'm fighting with some engine noise issues in the in-boat speakers only, but I hope to have that fixed by this weekend.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0201.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0204.jpg

[core-rider]

Finally got around to getting a on-board charger and installing it. I mounted it on the driver's side beside the rear bench seat on the hull. Come to find out CC installs some kind of Dynamat material on the side of the hull to dampen noise I guess. Used the same 1/2" HDPE that was used on the rest of this project and glued it to the hull with Liquid Nails. It wasn't quite cured yet when I mounted the charger so tat is why I have a small piece of wood blocking the panel up. (it will come out in a few days) I went with the Pro Mariner ProSport 20+ even though I really needed a 30 amp charger. If this one bites the bullet I will get the 30 amp model, but I was trying to save some money here and found a great deal on this one. I lengthened the wires going to the passenger side batteries without their extensions using 12 gauge duplex safety cable. I don't like the way Pro mariner does their extensions and my way is just a cleaner, better installation IMHO. It does void the warranty, but I'm not really concerned about that. Pics...

This is the mounting location...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0244.jpg

Carpet removed and you can see the foil on the Dynamat...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0245.jpg

Board and charger in place, wires ran to batteries...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0248.jpg

Few shots of interior going back in...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0249.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0250.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0251.jpg

Shot from aft compartment...
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0252.jpg

[ski4evr]

Holy Smokes Batman!!!! That is awesome work!!!

[obd666]

nice work indeed, and by the looks of it your system is straight beast

[core-rider]

Now just waiting on my pair of Rev410's and this little project will be complete!

[bhectus]

looks great man! Quick question: Did you wire your amp power supply to the + battery terminal directly or to "common" on your Perko? And where is your ground mounted to? I have mine wired to my common on the perko and the ground to the block on one of the motor mount studs and I'm getting some engine noise through my tower speakers which are powered by my amp. Only happens when the engine is running. (sorry to threadjack, your work is amazing!)

[core-rider]

The amp power is going directly to the house batteries. I used the factory power and ground to the Perko switch. My starting battery is on "1" of the switch, house batteries on "2", and the common goes to the engine. This allows me to separate the starting and house batteries for use, but also use either of them for running the engine if needed. After thinking about it a bit I need to add a battery disconnect for the amp power just in case I need to shut them off quickly. That's the one thing I didn't do. I plan to use one of the factory switches I removed for that. The pic below shows the factory cables on the left running towards the Perko switch. You can also see the 0 gauge cables going to the battery for the amps. I just need to add a switch to disconnect the amp power.
http://i305.photobucket.com/albums/nn225/core-rider/Battery%20compartment/IMG_0183.jpg

[n3]

Jason,

Very impressive!!

Mark

[bhectus]

Thanks for the detailed explanation with pics Jason. That totally helps. Looks like i need to do some re-wiring.

[core-rider]

No problem man... Forgot to mention if your HU, EQ, etc are not all coming from the same power/ground source as the amps that might cause noise. I had the same problem with my in-boat speakers. Moved the power for the EQ and HU to my distribution lock for the amps and the noise disappeared. Something about long ground loops causes this.

[core-rider]

Little update to this project... One of the main reasons for this whole project.... Rev410's! Just picked them up. Now time to pull them apart for some modifications. More pics to come!
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0316.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0319.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0320.jpg

[core-rider]

Got the modifications done to my Rev410's! Painted the grills black and rotated them 45 deg. (I'm not a big fan of the Maltese Cross look and the wifey came up with this idea which I think looks good), powder coated the mounts black, and installed Neutrik connectors like the Pro485 had because I can't use the though clamp wiring design. Now I just have to re-pull the wires in the tower (upgrading to 12 gauge wire) and mount the pods.

The inside of the tape lines mark the inner ribs inside the pod. I used them as reference for drilling the hole for the Neutrik connectors. Got to say cutting holes in brand new $1200 speakers is almost more pressure than cutting holes in a boat!
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0321.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0322.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0324.jpg

Connectors installed and wiring. I used some stainless 6x32 machine screws with nylock nuts, and sealed them up with some 3M 5200 sealant. I was going to make some aluminum plates to back-up the pod for strength, but these things are beefy. The pod thickness is about 1/4" so I didn't bother.
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0326.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0327.jpg

I sealed up the factory wiring hole with some more 3M 5200...
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0329.jpg

Powder coated mount brackets...
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0331.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0332.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0333.jpg

Grills masked off, just need to scuff and paint them...
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0334.jpg

Painted...
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0335.jpg

Grills installed and ready to mount speaker pods. I need to get some black touchup paint to paint the stainless screw heads on the grills and clean up some fine areas on the grills as well.
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0341.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0338.jpg
http://i305.photobucket.com/albums/nn225/core-rider/Project%20Can%20You%20Hear%20Me%20Now/IMG_0340.jpg